Effects of sintering temperature on physical and compositional properties of alpha-tricalcium phosphate foam.

Effects of sintering temperature on the physical and compositional properties of alpha-TCP foam fabricated using the polyurethane foam method were examined. When a polyurethane foam coated with alpha-TCP slurry was sintered at 1,400-1,550 degrees C, alpha-TCP foam having basically the same fully interconnected porous structure was produced although shrinkage occurred with increasing sintering temperature. On porosity of the alpha-TCP foam, a higher foam porosity of 95% was obtained when sintered at 1,400 degrees C as compared to the 90% porosity obtained at a higher sintering temperature of 1,550 degrees C. Further, at 1,500 degrees C or higher temperature, frame became dense with disappearance of micropores. On compressive strength, it increased from approximately 50 to 250 kPa when sintering temperature was increased from 1,400 to 1,550 degrees C. Nonetheless, no compositional changes were observed even when the alpha-TCP foam was cooled in the furnace without quenching process. In light of the results obtained, it was concluded that alpha-TCP foam fabricated using the polyurethane method was useful as a bone substitute and/or scaffolding material for tissue engineering. Besides, alpha-TCP foam could be useful as a precursor for the fabrication of other calcium phosphate foams.

Fabrication of low-crystallinity hydroxyapatite foam based on the setting reaction of alpha-tricalcium phosphate foam.

Low-crystallinity hydroxyapatite (HAP) foam is an ideal material for bone substitutes and scaffolds for bone tissue regeneration, because its interconnected pores provide the space for cell growth and tissue penetration, and its composition induces excellent tissue response and good osteoconductivity. In this study, the feasibility of low-crystallinity HAP foam fabrication was evaluated based on the phase transformation reaction or the so-called dissolution-reprecipitation reaction of alpha-tricalcium phosphate (alpha-TCP) foam granules. When alpha-TCP foam granules were placed in water at 37 degrees C for 1 day, no reaction was observed. However, alpha-TCP foam granules set to form low-crystallinity HAP by treating it hydrothermally at 200 degrees C. The network of fully interconnected pores was retained, and porosity was as high as 82%. Pore size ranged from 50 to 300 mum with an average pore size of 160 mum. Compressive strength was 207 kPa. Although no setting reaction was observed at 37 degrees C, the setting reaction caused by the hydrothermal treatment of alpha-TCP foam granules allowed the fabrication of any shape of low-crystallinity HAP. Therefore, this method may be useful for the fabrication of bone substitutes and scaffolds in bone tissue regeneration.

Fabrication of porous low crystalline calcite block by carbonation of calcium hydroxide compact.

Calcium carbonate (CaCO(3)) has been widely used as a bone substitute material because of its excellent tissue response and good resorbability. In this experimental study, we propose a new method obtaining porous CaCO(3) monolith for an artificial bone substitute. In the method, calcium hydroxide compacts were exposed to carbon dioxide saturated with water vapor at room temperature. Carbonation completed within 3 days and calcite was the only product. The mechanical strength of CaCO(3) monolith increased with carbonation period and molding pressure. Development of mechanical strength proceeded through two steps; the first rapid increase by bonding with calcite layer formed at the surface of calcium hydroxide particles and the latter increase by the full conversion of calcium hydroxide to calcite. The latter process was thought to be controlled by the diffusion of CO(2) through micropores in the surface calcite layer. Porosity of calcite blocks thus prepared had 36.8-48.1% depending on molding pressure between 1 MPa and 5 MPa. We concluded that the present method may be useful for the preparation of bone substitutes or the preparation of source material for bone substitutes since this method succeeded in fabricating a low-crystalline, and thus a highly reactive, porous calcite block.

Effects of sintering temperature over 1,300 degrees C on the physical and compositional properties of porous hydroxyapatite foam.

Porous hydroxyapatite (HAP) foam permits three-dimensional (3D) structure with fully interconnecting pores as well as excellent tissue response and good osteoconductivity. It is therefore thought to be a good candidate as scaffold material for bone regeneration and as a synthetic bone substitute material. To fabricate better porous HAP foam, improved physical and structural properties as well as higher osteoconductivity are desired. In the present study, the effects of sintering temperature on the physical and compositional properties of porous HAP foam were evaluated by employing high sintering temperature starting at 1,300 degrees C up to 1,550 degrees C. The mechanical strength of porous HAP foam increased with sintering temperature to reach the maximum value at 1,525 degrees C, then decreased slightly when sintering temperature was further increased to 1,550 degrees C. Alpha tricalcium phosphate (alpha-TCP) was formed, and thus the porous HAP foam became biphasic calcium phosphate. Biphasic calcium phosphate consisting of both alpha-TCP and HAP had been reported to show higher osteoconductivity than HAP alone. We therefore recommend 1,500-1,550 degrees C as the sintering temperature for porous HAP foam since this condition provided the most desirable physical properties with biphasic calcium phosphate composition.

Fabrication of hydroxyapatite block from gypsum block based on (NH4)2HPO4 treatment.

The aim of this study was to evaluate the feasibility of fabricating low-crystalline, porous apatite block using set gypsum as a precursor based on the fact that apatite is thermodynamically more stable than gypsum. When the set gypsum was immersed in 1 mol/L diammonium hydrogen phosphate aqueous solution at 100 degrees C, it transformed to low-crystalline porous apatite retaining its original shape. The transformation reaction caused a release of sulfate ions due to an ion exchange with phosphate ions, thus leading to a decrease in the pH of the solution. Then, due to decreased pH, dicalcium phosphate anhydrous--which has similar thermodynamic stability at lower pH--was also produced as a by-product. Apatite formed in the present method was low-crystalline, porous B-type carbonate apatite that contained approximately 0.5 wt% CO3, even though no carbonate sources--except carbon dioxide from air--were added to the reaction system. We concluded therefore that this is a useful bone filler fabrication method since B-type carbonate apatite is the biological apatite contained in bone.